Environmental and Thermal Barrier Coating to Protect a Pre-Coated Substrate

United States Patent Application

An apparatus and method to improve protection of a pre-coated substrate in various environments. The apparatus may include a pre-coated substrate having a substantially porous vapor-deposited coating and one or more non-porous ceramic oxide-based layers applied to the pre-coated substrate by a non-vapor deposition technique. The coefficient of thermal expansion corresponding to the non-porous ceramic oxide-based layer may substantially match the thermal expansion coefficient of the vapor-deposited coating to facilitate thermal compatibility between the two. Further, the non-porous ceramic oxide-based layer may infiltrate pores of the substantially porous vapor-deposited coating to provide a well-bonded hermetic seal that limits fluid access to the pre-coated substrate through the substantially porous vapor-deposited coating.

U.S. GOVERNMENT INTEREST
[0002] This invention was made with government support under Contract No. DEFG-0203ER83620 awarded by the U.S. Department of Energy. The government has certain rights in the invention.